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Prep as you said. Weld one pass on one side. Flip over & grind second side until your into the first weld. Then weld second side. Alternate passes on each side til done. Reinforcement can't hurt but make sure it's comfortable in your hand. After it cools.

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Make sure it's comfortable in your hand after it cools? Haaahaa, I have done it before and I will do it again.

I purchased one of those infrared temp guns to read temps by pointing the little red laser at the part. Well aluminum is kind of shiny plus I went the cheep way on the temp gage.

First day, I welded up some aluminum, pointed that thing at the weld and part in general,,, WHAT, a 100 degrees???? That can't be right.... and picked up the part with a bare hand. My hand sounded like an egg frying.

I knew it, but that gage made me stupid for a moment. I returned it that day.

I almost want to fix that wrench and give it back to the guy that tossed it out. He works in our maintenance department and he is a really good person. They weld some mild steel but thats it.

I have been able to get some stainless jobs from my work place, not much, mostly because I can't take credit cards, I don't have insurance, oh and the biggie, I'm not a certified welder. There is no use trying to explain certifications to the educated engineers.

The last two jobs they paid me by adding extra hours onto my regular pay. It would be an opportunity for me to get the word out that I can do aluminum.

I'll see how it turns out.

Thanks for the input, and I would like to hear others as well.

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Hardrock40 wrote "I almost want to fix that wrench and give it back to the guy that tossed it out. He works in our maintenance department and he is a really good person. They weld some mild steel but thats it."

Some places throw broken stuff out because the liability isn't worth it. A fixed wrench breaks & someone gets hurt? Company is liable. I would fix it & keep it. You'll find a use for it. Just remember that you welded it when you have a 6 foot pipe on it for leverage.

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Hardrock40 wrote "I almost want to fix that wrench and give it back to the guy that tossed it out. He works in our maintenance department and he is a really good person. They weld some mild steel but thats it."

Some places throw broken stuff out because the liability isn't worth it. A fixed wrench breaks & someone gets hurt? Company is liable. I would fix it & keep it. You'll find a use for it. Just remember that you welded it when you have a 6 foot pipe on it for leverage.